Poly-bonded building panels

ABSTRACT

A light weight single layer building panel with a peripheral frame of metal, wood ceramic or plastic, with or without internal members, deriving its structural integrity from the peripheral frame and internal members if used, the layer of expanded foam and the bonding of the expanded foam to the peripheral frame and internal members if used. This unique building panel can be coupled together with more of the like panels and used as a single layer to construct a wall, ceiling, roof, floor or complete building and can be used in conjunction with decorative veneers. The design allows for the building panel to be used in its own building system or as much or as little of the technology as needed can be employed into convention construction projects.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a structural building panel, method of fabricating the structural building panel and method of constructing a building employing the structural building panel. More particularly, the present invention relates to a framed building panel which has increased structural integrity and is operable to construct a wall, roof, floor, ceiling, room or building and the method of fabricating the structural building panel.

2. Description of the Prior Art

The construction industry as a whole is continually seeking ways to reduce costs associated with time, labor and materials utilized to construct a building, wall, room, floor, ceiling and roof Historic techniques used have for the most part been prefabrication of portions of a structure with conventional materials using conventional construction methods, then transporting the fabrication portion of the building to the construction site. Problems with such techniques include misalignment of prefabricated building portions at the construction site and damage to the prefabricated building portions during transit. Another problem with these techniques is that using conventional materials has proven to cumbersome and to expensive to be competitive.

These techniques typically also require that the structural integrity of the prefabricated portion of the building is derived solely from the frame of the prefabricated portion. In some instances, the structural integrity of the prefabricated portion of the building and the building itself is further derived from the specific way a prefabricated portion needs to be assembled with another portion of the building connection, fasteners, and other coupling mechanisms specific to using the prefabricated portion.

There is a need for a building panel having structural integrity, there is a need for a method of fabrication of a building panel having structural integrity, and a method of constructing a building utilizing a building panel with structural integrity. There is a need for a building panel having structural integrity, there is a need for a method of fabrication of a building panel having structural integrity, and a method of constructing a building utilizing a building panel with structural integrity, where the structural integrity is derived from the layer of expanded foam, the horizontal stud members and the vertical stud members or the diagonal stud members and the bonding of expanded foam to vertical stud members and horizontal stud members or diagonal stud members. There is a need for vertical and horizontal stud members or diagonal members to form a frame. There is a need for expanded foam to define an interior building side of the building panel and an exterior building side of the building panel. There is a need for the building panel having structural integrity to couple to another building panel having structural integrity. There is a need for the building panel to couple to or interlock with an adjacent building panel employing a coupling or an interlocking stud. There is a need for the building panel to be held in an upright position employing a track secured to the floor with screws, bolts, welds, anchors, adhesives or the like.

SUMMARY OF THE INVENTION

In one present embodiment of the invention, a building panel having structural integrity, a method of fabricating the building panel having structural integrity, and a method of constructing a building employing the building panel having structural integrity are provided. The building panel having structural integrity is a single layer building panel that derives its structural integrity from expanded foam forming the layer that bonds to horizontal stud members and vertical stud members or diagonal members, the horizontal stud members and the vertical stud members or the diagonal stud members and the bonding of the expanded foam to the horizontal stud members and the vertical stud members or the diagonal stud members. The vertical stud members and the horizontal stud members or diagonal stud members can be provided at the edges of the building panel and together the horizontal stud members and the vertical members or the diagonal members form the peripheral frame for the building panel. The horizontal members and the vertical stud members or the diagonal members are bonded to the expanded foam using temperatures and pressures above ambient. Building panels can be connected to one another to construct a structure or any portion of a structure such as a wall, floor, roof or ceiling, using members at the edges having an interlocking mechanism. One or more building panels can be inserted in a vertical position into one or more tracks secured to a floor.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages and capabilities of the present invention will be more apparent with reference to the detailed description and appended figures in which:

FIGS. 1A-1B are front and side views of a building panel having structural integrity in accordance with the present invention.

FIG. 2 is a front view of a building panel having structural integrity with a diagonal member in accordance with the present invention.

FIG. 3 is a front view with a building panel having structural integrity with an internal vertical member in accordance with the present invention.

FIG. 4 is a top view of an interlocking stud member in accordance with the present invention.

FIG. 5 is a top view of an interlocking stud member with a utility conduit in accordance with the present invention.

FIG. 6 is an end view of a track section in accordance with the present invention.

FIG. 7 is a side view of an anchor in accordance with the present invention.

FIG. 8 is an end view of an eave lock section in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be embodied in many different forms and should not be construed to be limited to the embodiment here described. The present invention is more fully described with reference to the accompanied drawings and descriptions.

In one embodiment of the present invention, a building panel having structural integrity, a method of fabricating a building panel having structural integrity, and a method of constructing a building utilizing a building having structural integrity are provided. The building panel having structural integrity is a single layer building panel that derives its structural integrity from expanded foam forming the layer that bonds to horizontal stud members and vertical stud members or the diagonal stud members, the horizontal stud members and the vertical stud members or the diagonal stud members, and the bonding of the expanded foam to the horizontal stud members and the vertical stud members or the diagonal stud members. The expanded foam is bonded to the horizontal and vertical stud members using temperatures and pressures above ambient. Portions of a structure or a structure such as a wall, floor, ceiling, roof or building can be constructed by joining the building panels using members at the edges with interlocking mechanism. One or more building panels can be inserted in a vertical position into one or more tracks secured to a floor.

Referring to FIG. 1A, in one embodiment of the present invention, top horizontal stud member 102 and bottom horizontal stud member 103 are aligned in a parallel position at the upper and lower periphery of building panel 101 to form the top and bottom of building panel 101. In one embodiment of the present invention, top horizontal stud member 102 and bottom horizontal stud member 103 are aligned in a parallel position at a predetermined distance from one another. In one embodiment of the present invention, right vertical stud member 105 and left vertical stud member 104 are aligned in a parallel position at the right and the left periphery of the building panel 101 to form the right side and the left side of the building panel 101. In one embodiment of the present invention, right vertical stud member 105 and left vertical stud member 104 are aligned in a parallel position at a predetermined distance from one another. In one embodiment of the present invention, the vertical stud members 105 and 104 extend the height of the building panel 101 and the horizontal stud members 102 and 103 extend the length of the building panel 101. In one embodiment of the present invention, the vertical stud members 105 and 104 of the building panel 101 are configured to interlock with a vertical stud member of an adjacent building panel 101 to form a wall, ceiling, roof or floor of a structure.

Referring to FIG. 1A, in one embodiment of the present invention, the top horizontal stud member 102, bottom horizontal stud member 103, right vertical stud member 105, and left vertical stud member 104 form a frame around panel member 106. In one embodiment of the present invention, a first end portion of the top horizontal stud member 102 squarely abuts a first end portion of the left vertical stud member 104. In one embodiment of the present invention, a second end portion of the top horizontal stud member 102 squarely abuts a first end portion of the right vertical stud member 105. In one embodiment of the present invention, a first end portion of the bottom horizontal stud member 103 squarely abuts a second end portion of the left vertical stud member 104. In one embodiment of the present invention, a second end portion of the bottom horizontal stud member 103 squarely abuts a second end portion of the right vertical stud member 105. In one embodiment of the present invention, the members can be coupled with means such as but not limited to: screws, bolts, welds, adhesive bonds and the like.

Referring to FIGS. 1A and 1B, in one embodiment of the present invention, panel member 106 extends to and bonds to the inner side of each of the top horizontal stud member 102, bottom horizontal stud member 103, right vertical stud member 105 and left vertical stud member 104.

Referring to FIGS. 1A and 1B, in one embodiment of the present invention, exterior panel side 108 of panel member 106 is a flat plane extending past and running parallel to the forward side walls of horizontal stud members 102 and 103 and vertical stud members 104 and 105. In one embodiment of the present invention the right edge of exterior panel side 108 extends to the outside edge of the forward side wall of right vertical stud member 105 and runs parallel with the outside edge of forward side wall of vertical stud member 105 from the abutment of vertical stud member 105 and the top horizontal stud 102 vertically to the abutment of vertical member 105 and the bottom horizontal member 103. In one embodiment of the present invention the left edge of exterior panel side 108 extends to the outside edge of the forward side wall of the left vertical stud member 104 and runs parallel with the outside edge of the forward side wall of the left vertical stud member 104 from the abutment of left vertical stud member 104 and top horizontal stud member 102 vertically to the abutment of left vertical stud member 104 and bottom horizontal stud member 103. In one embodiment of the present invention the top edge of exterior panel side 108 extends to the inside edge of the forward side wall of the top horizontal stud member 102 and runs parallel to the inside edge of the forward side wall of the top horizontal stud member 102 from the abutment of the top horizontal stud member 102 and right vertical stud member 105 to the abutment of the top horizontal stud member 102 and the left vertical stud member 104. In one embodiment of the present invention the bottom edge of the exterior panel side 108 extends to the inside edge of the forward side wall of the bottom horizontal stud member 103 and runs parallel to the inside edge of the forward side wall of the bottom horizontal stud member 103 from the abutment of the bottom horizontal stud member 103 and right vertical stud member 105 to the abutment of the bottom stud horizontal stud member 103 and left vertical stud member 104.

Referring to FIGS. 1A and 1B, in one embodiment of the present invention, interior panel side 107 of panel member 106 is a flat plane extending past and running parallel to the back side walls of horizontal stud members 102 and 103 and vertical stud members 105 and 104. In one embodiment of the present invention the periphery of interior panel side 107 and the periphery of the interior panel side of building panel 101 are substantially the same.

Referring to FIGS. 1A and 1B, the illustrations show a building panel 101 with top horizontal member 102 and bottom horizontal member 103 along with left vertical stud member 104 and right vertical stud member 105 and expanded foam 106. FIG. 1B, illustrates the interior panel side 107 and exterior panel side 108. In FIG. 1A, top horizontal stud member 102, bottom horizontal stud member 103, left vertical stud member 104 and right vertical stud member 105 can be constructed of metal, wood, ceramic or plastic. In an embodiment of the present invention top horizontal stud member 102, bottom horizontal stud member 103, left vertical stud member 104 and right vertical stud member 105 are constructed of either conventional stud, a C-shaped stud, U-shaped channel, L-shaped angle material or an interlocking stud. The expanded foam panel member 106 can be made of expanded foam, including, but not limited to, polyurethane-based foam, polyurea-based foam, polystyrene-based foam, polyisocyanurate-based foam, and the like. In one embodiment of the present invention left vertical stud 104 and right vertical stud 108 of the building panel 101 are configured to interlock with a vertical stud member of an adjacent panel 101 to form a floor, wall, ceiling, roof or building.

Referring to FIGS. 1A and 1B, exterior panel side 108 can be extended past and covering the forward sidewalls of top horizontal member 102 bottom horizontal member 103 left vertical member 104 and right vertical member 105 eliminating the need for sheathing, moisture shed or vapor barriers in construction.

Referring to FIGS. 1A, 2 and 3, top horizontal member 102 abuts to left vertical member 104, left vertical member 104 abuts to bottom horizontal member 103, bottom horizontal member 103 abuts to right vertical 105 and right vertical member 105 abuts to top horizontal member 102 to form the frame at the outer perimeter of the building panel. In FIGS. 1A, 2 and 3 the building panel 101 can have any shape perimeter with any number of sides to accommodate any shape of construction or style of architecture. In FIGS. 1A, 2 and 3 all members of the framed perimeter can be straight or curved or in any combination of thereof In FIGS. 1A,2 and 3 foam member 106 can be flat, curved, bent in an angle or in any combination thereof to accommodate any shape of construction or style of architecture. In FIGS. 1A, 2 and 3 the points of abutment can be coupled by means such as but not limited to; screws, welding, adhesive bonds and bolts.

Referring to FIGS. 1A, 2 and 3 electrical components including but not limited to electrical boxes, conduits, low voltage wiring, high voltage wiring, telephone connections, shielded communications cable, fiber optics and the like can be preset in foam member 106 during fabrication or may be added to the building panel after fabrication.

Referring to FIGS. 1A, 2 and 3 plumbing components including but not limited to vent pipes, hot water supply lines, cold water supply lines, water heater exhaust lines, drain lines and the like can be preset in foam member 106 during fabrication or can be added to the building panel after fabrication.

Referring to FIGS. 1A, 2 and 3, heating and cooling components including but not limited to vent pipes, exhaust ducts, fresh air ducts, combustible air ducts, control wiring, piping for radiant heating systems, piping for radiant cooling systems, return air ducts, supply air ducts and the like can be preset in foam member 106 during fabrication or can be added to the building panel after fabrication.

Referring to FIGS. 1A, 2 and 3, puncture resistant components including but not limited to a wire grid, a metal mesh, a plastic mesh, a fiberglass mesh or the like can be preset in foam member 106 during fabrication or can be added to the building panel after fabrication.

Referring to FIG. 1A expanded foam member 106 extends to and, in the case of hollow members fills, and bonds to the inner side of each the top horizontal member 102, bottom horizontal member 103, left vertical member 104 and right vertical member 105.

Referring to FIG. 2 expanded foam member 106 extends to and, in the case of hollow members fills, and bonds to the inner side of each the top horizontal member 102, bottom horizontal member 103, left vertical member 104, right vertical member 105 and both inner sides of diagonal member 201.

Referring to FIG. 3 expanded foam member 106 extends to and, in the case of hollow members fills, and bonds to the inner side of each the top horizontal member 102, bottom horizontal member 103, left vertical member 104, right vertical member 105 and both inner sides of vertical member 301.

Referring to FIGS. 1A, 1B, 2 and 3 building panel 101 defines the perimeter of the building and face 107 defines the interior building surface or wall space to adhere cosmetic veneers to, and face 108 defines the exterior building surface or wall space to adhere cosmetic veneers to.

Referring to FIGS. 4 and 6 an exemplary top view of an interlocking stud member 401 with a Z-shaped cross section on face 402 with one sidewall 403 and one sidewall 404 configured such that when a like stud member is rotated 180 degrees and interlocked with the first stud member and set in track 601 it maintains the structural integrity of the construction between panels.

Referring to FIGS. 5 and 6 an exemplary top view of an interlocking stud 501 with a Z-shaped cross section on face 502 with a conduit wall 505 and one sidewall 503 and one sidewall 504 configured such that when a like stud member is rotated 180 degrees and interlocked with the first stud member and set in track 601 it maintains the structural integrity of the construction between panels and forms a utility conduit between panels.

Referring to FIGS. 4 and 5 the Z-shaped cross section 402 and the Z-shaped cross section 502 can rotated 180 degrees and interlocked with the Z-shaped cross section of an adjacent stud member 401 or 501 having the same configuration to create walls, floors, ceilings and roofs of any structure including, but not limited to, conventional construction, modular construction, tilt up construction, building panel construction and the like.

Referring to FIGS. 6 and 7 the track 601 has a U-shaped configuration with a flat base 602 and upward sidewalls 603 and 604 and can be fabricated in various lengths with pre-set holes in the base 602 at regular intervals for the insertion of anchor 701 through the track and into the foundation or can be secured to the floor with one or a combination of screws, bolts, welds, adhesives and the like.

Referring to FIGS. 6 and 7 the anchor 701 has a flat metal disc 702, larger then the pre-set holes in track 601, squarely abutting and affixed in the center to an L-shaped metal rod 703 configured as such as to allow for insertion through the pre-set holes in the flat base 602 of track 601 and into the foundation.

Referring to FIGS. 1A, 1B and 8 the eave lock 801 is a metal strip with a flat base 802 and angled sides 803 and 804 and is fabricated in various lengths and assembled end to end to run the full length of the eave of the building exterior at the juncture of the wall and the underside of the roof with side 803 in full contact with exterior panel side 108 and is screwed or affixed to vertical stud members 104 and 105 at regular intervals. Eave lock 801 side 804 is installed the length of the building in full contact side 107 of a roof panel and is screwed or affixed to vertical stud members 104 and 105 at regular intervals. Roof panels can also be affixed to wall panels with any of other means including but not limited to trusses, rafters, straps or the like.

Referring to FIGS. 1A, 6, 7 and 8 In one exemplary embodiment of the present invention track 601 is configured as the outer perimeter of a building and secured to the foundation with anchor 701 or other means. Building panel 101 is stood upright within the sidewalls 603 and 604 of the track 601. A second building panel 101 is lifted over the sidewalls 603 and 604 of the track 601 and the vertical interlocking members 105 of the first panel and 104 of the second panel are interlocked prior to inserting the second panel between sidewalls 603 and 604 of the track 601. The interlocking of vertical member 105 of one panel to vertical member 104 of an adjacent panel and insertion of the interlocked panels into track 601 secures the building panels to one another in an upright position. A roof constructed of the building panels 101 can be secured to walls constructed of building panels 101 by employing the eave lock 801 or by other means. Building panels 101 can be employed in the construction of types of buildings including but not limited to houses, commercial buildings, strip malls, cold storage facilities, apartment buildings and office buildings or any portion thereof including but not limited to walls, floors, ceilings and roofs.

In an exemplary method of fabrication of the present invention a peripheral frame of stud members is placed in a mold press and expanded foam is injected in and distributed consistently within, and bonded to, a peripheral frame. In the exemplary method of fabrication of the present invention the building panel is removed from the press.

In an embodiment of the present invention the density of the expanded foam is directly related to the pressure applied by the mold press during the thermoset reaction. For example, in one embodiment of the present invention, the pressure is about 1 psi to about 15 psi. In one embodiment of the present invention, the pressure is about 3 psi to about 10 psi. In one embodiment of the present invention, the pressure is about 5 psi to about 7 psi. In one embodiment of the present invention, the pressure is about 6 to 29 psi.

As known to those of ordinary skill in the art, once thermoset materials form cross links as a result of applied heat and pressure the thermoset material cannot be reheated. Thus, once heat and pressure are applied to the reactants in the mold press adjacent to the frame members to form the material, the material is cured and bonded to the frame members with an improved bonding strength or peel strength over conventional expanded foam/stud designs.

In one embodiment of the present invention, the moisture content of a wood stud can be utilized to react with excess isocyanate in the polyurethane material to form additional urethane linkages resulting in an improved bond strength. In one embodiment stud members can be surface treated any of several techniques known in the art including but not limited to corona discharge, plasma treatment, sand blasting, brush tumbling and the like, resulting in increased adhesion between the expanded foam and the stud members.

In an embodiment of the present invention, the density of the expanded foam can be based on the specific application of the building panel. The density of the expanded foam is directly related to the pressure applied to the mold press during the thermoset reaction and any suitable temperature and pressure can be provided that allows the reaction to proceed. In one embodiment the temperature range is from about 32 degrees F. to about 180 degrees F. In one embodiment the temperature range is from about 75 degrees F. to about 170 degrees F. In one embodiment the temperature range is from about 75 degrees F. to about 150 degrees F. In one embodiment the temperature range is from about 80 degrees F. to about 105 degrees F. 

1. A building panel having structural integrity, comprising: a peripheral frame including a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a first end portion of the top horizontal stud member joins to a first end portion of the left vertical stud member, a second end portion of the top horizontal stud member joins to a first end portion of the right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of the left vertical stud member, and a second end portion of the bottom horizontal stud member joins to a second end of the right vertical stud member; and an expanded foam member formed at least within the peripheral frame, wherein the expanded foam fills the peripheral frame, and is bonded to the peripheral frame, a first exposed side of the expanded foam defines an exterior building surface of the panel, and a second exposed side of the expanded foam defines an interior building surface of the building panel.
 2. The building panel of claim 1, wherein the structural integrity of the building panel is derived from the peripheral frame, the expanded foam member and the bonding of the expanded foam member to the peripheral frame.
 3. The building panel of claim 1, wherein the expanded foam is one of a thermoset material.
 4. The building panel of claim
 1. wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member, and the left vertical stud member is fabricated from one of metal, wood, ceramic, plastic or a combination thereof.
 5. The building panel of claim 1, wherein the top horizontal stud member, the bottom horizontal stud member, the right vertical stud member and the left vertical stud member is configured as one of; a conventional stud, a C-shaped stud, a U-shaped channel, a L-shaped angle material, a interlocking stud or a combination thereof.
 6. The building panel of claim 1, wherein a first side of the expanded foam defines the exterior building surface of the building panel.
 7. The building panel of claim 6, wherein a second side of the expanded foam defines the interior building surface of the building panel.
 8. The building panel of claim 7, wherein the expanded foam extends to the outer boundary of the peripheral frame.
 9. The building panel of claim 1, wherein at least one of the right vertical stud member and the left vertical stud member is an interlocking stud operable to interlock with an interlocking stud of an adjacent structural component.
 10. An interlocking stud comprising; a face having a Z-shaped configuration a first side wall extending away from the face and bending toward a second side wall at the farthest point away from the face a second side wall extending away from the face and bending toward a first side wall at the farthest point away from the face.
 11. The interlocking stud of claim 10, wherein the interlocking stud is operable to interlock with another interlocking stud having substantially the same configuration as the face of the interlocking stud.
 12. An interlocking stud with utility conduit comprising; a face having a Z-shaped configuration with a utility conduit extending there thru a first side wall extending away from the face and bending toward a second side wall at the farthest point away from the face a second side wall extending away from the face and bending toward a first side wall at the farthest point away from the face.
 13. The interlocking stud of claim 12, wherein the interlocking stud with utility conduit is operable to interlock with another interlocking stud having substantially the same configuration as the face of the interlocking stud.
 14. An improved modular building, said building comprising: a first set of building panels defining the perimeter of the modular building, wherein each of the building panels include a peripheral frame having a top horizontal stud member, a bottom horizontal stud member, a left vertical stud member, and a right vertical stud member, wherein a first end portion of the top horizontal stud member joins to a first end portion of the left vertical stud member, a second end portion of the top horizontal stud member joins to a first end portion of the right vertical stud member, a first end portion of the bottom horizontal stud member joins to a second end portion of the left vertical stud member, and a second end portion of the right vertical stud member; and an expanded foam member formed at least within the peripheral frame, wherein the expanded foam member fills the peripheral frame, and is bonded to the peripheral frame, a first exposed side of the expanded foam defines an exterior building surface of the panel, and a second exposed side of the expanded foam defines an interior building surface of the building panel, each of the building panels configured with an interlocking stud as the left vertical stud member and the right vertical stud member for interlocking with an adjacent building panel configured with an interlocking stud as the left vertical stud member and the right vertical stud member; a roof supported by, and secured to, the first set of building panels.
 15. The improved modular building of claim 14, wherein the roof is constructed from a second set of panels.
 16. The improved modular building of claim 14, further comprising a set of tracks, wherein each track in the set of tracks includes a base portion, a first track sidewall, a second track sidewall and pre-set holes at regular intervals in the base portion and is secured to the foundation of the modular building.
 17. The improved modular building of claim 14, further comprising a set of anchors, wherein each anchor in the set of anchors includes a L-shaped metal rod squarely abutting and affixed to the center of a metal disc and each anchor in the set of anchors is inserted L-shaped rod first through one of the pre-set holes in the base portion of the track and into the foundation until the metal disc affixed to the top of the anchor engages the base portion of the track and the base portion of the track engages the foundation.
 18. A system for securing a wall of a building to a foundation, comprising: a track including a base portion, a first track side wall, a second track side wall, and pre-set holes at regular intervals a set of anchors, wherein each anchor in the set of anchors includes a L-shaped metal rod squarely abutting and affixed to the center of a metal disc.
 19. The system of claim 18, wherein each anchor in the set of anchors is inserted L-shaped rod first through one of the pre-set holes in the base portion of the track and into the foundation until the metal disc affixed to the top of the anchor engages the base portion of the track and the base portion of the track engages the foundation.
 20. The system of claim 18, wherein the building panel is inserted within the first track side wall and the second track side wall of the track. 